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Old 05-09-2014
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1st big project, bronze thru-hull

My first big project on my little boat!

The Catalina 22 was built with a garden-hose style valve glassed directly to the hull for the sink and cockpit drain. I'm replacing it with a bronze thru-hull.

This might be mass overkill for a tiny boat that will be sailing on a tiny lake, but one of my goals with this boat is to learn how to do things The Right Way so I'll have the experience for future, larger boats.

So I've got a printout of Maine Sail's instructions, and a big pile of 1" bronze hardware:



Any tips, tricks, or advice?
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Old 05-09-2014
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Re: 1st big project, bronze thru-hull

I favor the taping and using studs on a G10 plate version as it is three less holes to leak and killer strong
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Old 05-09-2014
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Re: 1st big project, bronze thru-hull

The G10 plate arrives tomorrow.

Since the three holes are sealed and glassed over is leaking really an issue?

I do like the idea of three fewer holes, but then again the screw-through-the-hull thing seems like it would be bulletproof strong.
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Re: 1st big project, bronze thru-hull





The plate is NOT coming off the hull and the G10 holds a strong thread
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Old 05-09-2014
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Re: 1st big project, bronze thru-hull

I used G10 for the base too. I didn't use studs, nor did I use bolts through the hull.

I drilled through the bolt holes, then drilled a little larger area for the bolt heads so they would be recessed into the G10 plate.

Next time I haul out, I will have 6 or 7 more to replace and plan to install the same way. MaineSail's instructions were great help.
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Re: 1st big project, bronze thru-hull

Minnesail - Are you going to need to do some modifications to get rid the old fiberglass horn and make the hole the right size? Not sure what you mean by glassing over the studs. They should screw in from the outside of the hull. Can put some fairing over them for smoothness, but doesn't seal them. If you drill holes for the bolts that are the same size as the bolts, and use sealing material, it will be very water tight.
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Re: 1st big project, bronze thru-hull

I have Sikaflex 291 to use to seal the machine screws. I guess I didn't mean glass over the heads, I just meant to put some thickened epoxy over them. You're saying that's not necessary?

The existing fitting is on the keel slot, so it's on a sharply curved surfaced. I plan on putting the new thru-hull off to the side of that, on a flat part of the hull.



My plan is to cut off the "horn" and fill the hole with a thickened epoxy plug, then fiberglass over that plug on both sides.

I've never used epoxy or fiberglass before, so this weekend I'm going to play around a bit on some scrap wood to get the feeling for the stuff.
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Old 05-09-2014
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Re: 1st big project, bronze thru-hull

if you can get some chopped strand mat and make 3 or 4 little circles to fill the hole you're patching, that would be better. Wet them out thoroughly and stack them neatly in the hole. The foregoing sounds easier than it is.

I've not read Mainesail's article, but I have found that the shrink wrap plastic that is filling boatyard dumpsters everywhere this time of year makes a great backing material for filling a hole. It's got some body to it, and epoxy will not stick. Put a sheet against the hull, back that further with a piece of plywood, and jam it all in place with a stick and a wedge.

Edit to add: Holy heck that's a manly pile of bronze.
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Re: 1st big project, bronze thru-hull

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Originally Posted by Ritchard View Post
if you can get some chopped strand mat and make 3 or 4 little circles to fill the hole you're patching, that would be better. Wet them out thoroughly and stack them neatly in the hole. The foregoing sounds easier than it is.

I've not read Mainesail's article, but I have found that the shrink wrap plastic that is filling boatyard dumpsters everywhere this time of year makes a great backing material for filling a hole. It's got some body to it, and epoxy will not stick. Put a sheet against the hull, back that further with a piece of plywood, and jam it all in place with a stick and a wedge.

Edit to add: Holy heck that's a manly pile of bronze.
Ain't it though?

My wife got no end of giggle out of saying "full flow ball valve seacock"

Anyway, you're saying chopped strand mat would be a better plug that sticking in thickened epoxy? How about woven fiberglass, would that work? I already have that.
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Re: 1st big project, bronze thru-hull

Look at the diagram in step 8 of the link...

WEST SYSTEM | Projects | Fiberglass Boat Repair & Restoration - Repairing machined holes in fiberglass
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